Yaskawa -L User's_Manual

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YASKAWA SGML/SGDL (for position control) USER'S MANUAL AC Servomotor and Driver SGML Servomotor SGDL- P Servopack YASKAWA MANUAL NO. SIE-S800-15.31BThis manual covers the products of the SGML/SGDL, which feature superior functions and performance. This manual was designed to provide comprehensible information for users who are about to use a servo for the first time as well as for users who already have experience in using servos. This manual enables users to understand how to design, install, operate, and maintain a servo system. Keep this manual in a convenient location and refer to it whenever necessary in operating and maintaining the servo system. General Precautions Some drawings in this manual are shown with the protective cover or shields removed, in order to describe the detail with more clarity. Make sure all covers and shields are replaced before operat- ing this product. Some drawings in this manual are shown as typical example and may differ from the shipped product. This manual may be modified when necessary because of improvement of the product, modifica- tion or changes in specifications. Such modification is made as a revision by renewing the manual No. To order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative listed on the last page stating the manual No. on the front cover. YASKAWA is not responsible for accidents or damages due to any modification of the product made by the user since that will void our guarantee.NOTES FOR SAFE OPERATION Read this manual thoroughly before installation, operation, maintenance or inspection of the AC Servo Drives. In this manual, the NOTES FOR SAFE OPERATION are classified as "WARNING" or "CAUTION". WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious personal injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate personal injury and/or damage to the equipment. In some instances, items described in CAUTION may also result in a serious accident. In either case, follow these important items. iv! WARNING (WIRING) Grounding must be in accordance with the national code and consistent with sound local practices. Failure to observe this warning may lead to electric shock or fire. (OPERATION) Never touch any rotating motor parts or machine movable part during operation. Failure to observe this warning may result in personal injury. (INSPECTION AND MAINTENANCE) Be sure to turn OFF power before inspection or maintenance. Otherwise, electric shock may result. Never open the terminal cover while power is ON, and never turn ON pow- er when the terminal cover is open. Otherwise, electric shock may result. After turning OFF power, wait at least five minutes before servicing the product. Otherwise, residual electric charges may result in electric shock. CAUTION (RECEIVING) Use the specified combination of SERVOMOTOR and SERVOPACK. Failure to observe this caution may lead to fire or failure. (INSTALLATION) Never use the equipment where it may be exposed to splashes of water, corrosive or flammable gases, or near flammable materials. Failure to observe this caution may lead to electric shock or fire. (WIRING) Do not connect three-phase power supply to output terminals U V and 3 W Failure to observe this caution may lead to personal injury or fire. Securely tighten screws on the power supply and motor output terminals. Failure to observe this caution can result in a fire. Never change wiring while power is ON. Failure to observe this caution may result in electric shock or personal injury. V! CAUTION (OPERATION) To avoid inadvertent accidents, run the SERVOMOTOR only in test run (without load). Failure to observe this caution may result in personal injury. Before starting operation with a load connected, set up user constants suitable for the machine. Starting operation without setting up user constants may lead to overrun failure. Before starting operation with a load connected, make sure emergency- stop procedures are in place. Failure to observe this caution may result in personal injury. During operation, do not touch the heat sink. Failure to observe this caution may result in burns. (INSPECTION AND MAINTENANCE) Do not disassemble the SERVOMOTOR. Failure to observe this caution may result in electric shock or personal injury. Never change wiring while power is ON. Failure to observe this caution may result in electric shock or personal injury. viManual Contents This manual provides Series users with information on the following: Checking the product on delivery and basic applications of the servo. Servo applications. Selecting an appropriate servo for your needs and placing an order. Inspection and maintenance. Manual Structure All chapters in this manual are classified into one or more of three areas according to their contents: A, B, and C. Refer to the applicable chapters for the information you require. A: Chapters explaining how to select a servo: For users who wish to gain a basic understanding of Series products or who need to select an appropriate servo. B: Chapters explaining how to design a servo system: For users who are about to design, install, and operate a Σ-L Series Servo Control System. C: Chapters explaining maintenance: For users who are going to maintain and troubleshoot Σ-L Series products. Chapter Title Page Area CHAPTER 1 Basic Uses of Σ-L series Products 1 B Describes steps to take when product is received, plus basic wiring and application methods. CHAPTER 2 Applications of Σ-L series Products 27 B Describes the effective usage of Σ-L Series features according to application. CHAPTER 3 Using the Digital Operator 73 B Describes operating procedures for Σ-L Series servos, turning features ON and OFF, setting control constants, etc. CHAPTER 4 Servo Selection and Data Sheets 101 A, Describes selection methods for Σ-L Series servos and periph- erals and provides servo specifications. CHAPTER 5 Inspection, Maintenance, and Troubleshooting 179 Describes user maintenance and troubleshooting. APPENDIXES A Servo Adjustment 197 B, B List of I/O Signals 207 A, B, C List of User Constants 211 B, INDEX 215 A,B,C viiBasic Terms Unless otherwise specified, the following definitions are used: Servomotor: Σ-L Series SGML Servomotor Servopack: An amplifier (Trademark of Yaskawa servo amplifier "SGDL Servopack") Servodrive: A SGML Servomotor and an amplifier (SGDL Servopack) Servo system: A complete servo control system consisting of servodrive, host controller, and peripheral devices Visual Aids The following aids are used to indicate certain types of information for easier reference. Indicates references for additional information. Technical terms placed in bold in the text are briefly explained in a "TERMS" sec- TERMS tion at the bottom of the page. The following kinds of technical terms are explained: Technical terms that need to be explained to users who are not very familiar with servo systems or electronic devices and technical terms specific to Σ Series Ser- vos that need to be explained in descriptions of functions. The text indicated by this icon explains the operating procedure using hand-held type digital operator (Type: JUSP-OP02A-1). JUSP-OP02A-1 The text indicated by this icon explains the operating procedure using mount type digital operator (Type: JUSP-OP03A). JUSP-OP03A NOTE A Σ-L Series Servodrive alone cannot ensure the functionality and performance of the entire machine control system. It must be combined with an appropriate machine and host control- ler that the entire control system works properly. Therefore, carefully read the instruction manuals for the machine to be used before attempting to operate the servodrive. Yaskawa, 1998 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Yas- kawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, Yaskawa assumes no re- sponsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication. viiiCONTENTS CHAPTER 1 BASIC USES OF Σ-L SERIES PRODUCTS 1 1.1 Precautions 2 1.1.1 Notes on Use 2 1.2 Installation 4 1.2.1 Checking on Delivery 4 1.2.2 Installing the Servomotor 5 1.2.3 Installing the Servopack 8 1.2.4 Power Loss 10 1.3 Connection and Wiring 11 1.3.1 Connecting to Peripheral Devices 11 1.3.2 Main Circuit Wiring and Power ON Sequence 14 1.4 Conducting a Test Run 16 1.4.1 Test Run in Two Steps 16 1.4.2 Step 1: Conducting a Test Run for Motor without Load 18 1.4.3 Step 2: Conducting a Test Run with the Motor Connected to the Machine 22 1.4.4 Supplementary Information on Test Run 24 1.4.5 Minimum User Constants Required and Input Signals 25 CHAPTER 2 APPLICATIONS OF Σ-L SERIES PRODUCTS 27 2.1 Setting User Constants According to Machine Characteristics 30 2.1.1 Changing the Direction of Motor Rotation 30 2.1.2 Setting the Overtravel Limit Function 31 2.2 Setting User Constants According to Host Controller 33 2.2.1 Inputting Position Reference 33 2.2.2 Using Contact I/O Signals 37 2.2.3 Using Electronic Gear 39 2.3 Setting Up the Servopack 43 2.3.1 Using Autotuning Function 43 2.3.2 Setting Servo Gain 43 2.3.3 Using the Smoothing Function 45 2.3.4 Setting the Torque Reference Filter Time Constant 46 2.4 Setting Stop Mode 47 2.4.1 Dynamic Brake 47 2.4.2 Using Holding Brake 48 2.5 Forming a Protective Sequence 51 2.5.1 Using Servo Alarm Output 51 2.5.2 Using Servo ON Input Signal 52 2.5.3 Using Positioning Complete Signal 53 2.5.4 Handling of Power Failure 54 2.6 Special Wiring 56 2.6.1 Wiring Instructions 56 2.6.2 Wiring for Noise Control 58 2.6.3 Using More Than One Servo Drive 63 2.6.4 Using Regenerative Units 64 2.6.5 Using SGDL Servopack with High Voltage Line 66 2.6.6 Connector Terminal Layouts 68 CHAPTER 3 USING THE DIGITAL OPERATOR 71 3.1 Basic Operations 72 XCONTENTS 3.1.1 Connecting the Digital Operator 72 3.1.2 Resetting Servo Alarms 73 3.1.3 Basic Functions and Mode Selection 74 3.1.4 Operation in Status Display Mode 75 3.1.5 Operation in User Constant Setting Mode 76 3.1.6 Operation in Monitor Mode 81 3.2 Using the Functions 84 3.2.1 Operation in Alarm Trace-back Mode 84 3.2.2 Operation Using the Digital Operator 86 3.2.3 Autotuning 89 3.2.4 Clearing Alarm Trace-back Data 95 3.2.5 Checking Motor Type 96 3.2.6 Checking Software Version 97 CHAPTER 4 SERVO SELECTION AND DATA SHEETS 99 4.1 Selecting a Series Servo 101 4.1.1 Selecting a Servomotor 101 4.1.2 Selecting a Servopack 112 4.1.3 Selecting a Digital Operator 114 4.2 SGML Servomotor 115 4.2.1 Ratings and Specifications 115 4.2.2 Mechanical Characteristics 124 4.3 Servopack Ratings and Specifications 126 4.3.1 Ratings and Specifications 126 4.3.2 Overload Characteristics 129 4.3.3 Starting Time and Stopping Time 130 4.3.4 Load Inertia 130 4.3.5 Overhanging Loads 132 4.3.6 Power Consumption 133 4.4 Σ-L Series Dimensional Drawings 134 4.4.1 Servomotor Dimensional Drawings 134 4.4.2 Servopack Dimensional Drawings 147 4.4.3 Digital Operator Dimensional Drawings 150 4.5 Selecting Peripheral Devices 151 4.5.1 Selecting Peripheral Devices 151 4.6 Specifications and Dimensional Drawings of Peripheral Devices 156 4.6.1 Cable Specifications and Peripheral Devices 156 4.6.2 Motor Cables 159 4.6.3 Connector Kits 162 4.6.4 Brake Power Supply 166 4.6.5 Encoder Cables 168 4.6.6 CN1 Connector 172 4.6.7 Connector Terminal Block Converter Unit 174 4.6.8 Cable With CN1 Connector and One End Without Connector 176 4.6.9 Circuit Breaker 176 4.6.10 Noise Filter 177 4.6.11 Magnetic Contactor 178 xiCONTENTS 4.6.12 Surge Suppressor 179 4.6.13 Regenerative Unit 180 4.6.14 Cables for Connecting PC and Servopack 181 CHAPTER 5 INSPECTION, MAINTENANCE, AND TROUBLESHOOTING 185 5.1 Inspection and Maintenance 186 5.1.1 Servomotor 186 5.1.2 Servopack 187 5.2 Troubleshooting 188 5.2.1 Troubleshooting Problems with Alarm Display 188 5.2.2 Troubleshooting Problems With No Alarm Display 200 5.2.3 Internal Connection Diagram and Instrument Connection Examples 201 APPENDIXES A Servo Adjustment 203 A.1 Σ-L Series AC Servopack Gain Adjustment 204 A.1.1 Series AC Servopacks and Gain Adjustment Methods 204 A.1.2 Basic Rules for Gain Adjustment 205 A.2 Adjusting a Position-control Servopack 206 A.3.1 Adjusting Using Auto-tuning 206 A.3.2 Manual Adjustment 207 A.3 Gain Setting References 210 A.4.1 Guidelines for Gain Settings According to Load Inertia Ratio 210 B List of I/O Signals 213 C List of User Constants 217 INDEX 220 xiiBASIC USES OF SERIES 1 PRODUCTS 1 This chapter describes the first things to do when Σ-L Series products are de- livered. It also explains the most fundamental ways of connecting and operat- ing Σ-L Series products. Both first-time and experienced servo users must read this chapter. 1.1 Precautions 2 1.1.1 Notes on Use 2 1.2 Installation 4 1.2.1 Checking on Delivery 4 1.2.2 Installing the Servomotor 5 1.2.3 Installing the Servopack 8 1.3 Connection and Wiring 11 1.3.1 Connecting to Peripheral Devices 11 1.3.2 Main Circuit Wiring and Power ON Sequence 14 1.4 Conducting a Test Run 16 1.4.1 Test Run in Two Steps 16 1.4.2 Step 1: Conducting a Test Run for Motor without Load 18 1.4.3 Step 2: Conducting a Test Run with the Motor Connected to the Machine 22 1.4.4 Supplementary Information on Test Run 24 1.4.5 Minimum User Constants Required and Input Signals 25 1BASIC USES OF Σ-L SERIES PRODUCTS 1.1.1 Notes on Use 1.1 Precautions This section provides notes on using Series products. 1.1.1 Notes on Use 2 1.1.1 Notes on Use NOTE Always note the following to ensure safe use. Two types of supply voltage are available, 100 V and 200 V. Both Σ-L Series Servomotor and Servopack have SERVOPACKO 100 V and 200 V types. Be sure to use the correct Voltage type. label Type NP SGDL-02AP 2001 V 100 V Always use the SGML Servomotor and SGDL Servopack in pairs. The SGML Servomotor cannot run without the Direct SGDL Servopack. connection Do not plug the SGML Servomotor directly into the commercial power supply. (Direct connection to the commercial power supply will damage the 200 V or 100 V power Servomotor.) supply Damage will result! Do not change wiring when power is ON. Always turn the power OFF before connecting or Extinguished disconnecting a connector. (Except for Digital Operator (Types: JUSP- Always turn the OP02A-1, JUSP-OP03A)) power OFF before connecting or disconnecting a connector. Note that residual voltage still remains in the Servopack even after the power is turned OFF. Even after the power is turned OFF, residual volt- age still remains in the capacitor inside the Servo- Careful! pack. If inspection is to be performed after the Residual voltage remains power is turned OFF, always wait at least 5 min- in capacitor utes to avoid the risk of an electrical shock. Wait at least 5 minutes 21.1 Precautions Always follow the specified installation method. Provide sufficient clearance The Servopack generates heat. Install the Servo- 10 mm pack that it can radiate heat freely. Note also : that the Servopack must be in an environment free from condensation, vibration and shock. Ambient temperature: 0 to 50°C Perform noise reduction and grounding properly. 1 If the signal line is noisy, vibration or malfunction Casing will result. Servopack Separate high-voltage cables from low-voltage cables. Servomotor line Use cables as short as possible. Use at least class 3 grounding (ground resistance or below) for the Servomotor and Servopack. Class 3 Never use a line filter for the power supply in the grounding motor circuit. Conduct a voltage resistance test under the following conditions. Voltage: 1,500 Vrms AC, one minute Braking current: 18 mA Conduct a Frequency: 50/60 Hz dielectric Voltage applied point: Between R, T terminals and strength test as described frame ground (connect terminals R and T securely.) on the left. Use a fast-response type ground-fault interrupter. For a ground-fault interrupter, always use a fast- Ground-fault interrupter response type or one designed for PWM invert- GOOD GOOD POOR ers. Do not use a time-delay type. Fast-response For PWM Time-delay type inverter type Do not perform continuous operation under overhanging load. Continuous operation cannot be performed by ro- Servomotor tating the motor from the load and applying regen- erative braking. Regenerative braking by the Ser- vopack can be applied only for a short period, such as the motor deceleration time. Regenerative braking continuously applied The Servomotor cannot be operated by turning the power ON and OFF. Frequently turning the power ON and OFF causes Servopack the internal circuit elements to deteriorate. Always start or stop the servomotor by using reference R Power pulses. supply Starting and stopping by turning power ON and OFF 3BASIC USES OF Σ-L SERIES PRODUCTS 1.2.1 Checking on Delivery 1.2 Installation This section describes how to check Series products on delivery and how to install them. 1.2.1 Checking on Delivery 4 1.2.2 Installing the Servomotor 5 1.2.3 Installing the Servopack 8 1.2.1 Checking on Delivery 1) When Series products are delivered, check the following items: Check Items Remarks Check if the delivered products are Check the types marked on the nameplates of the ones you ordered. Servomotor and Servopack (see the table below). Check if the motor shaft rotates If the motor shaft is smoothly turned by hand, it is smoothly. normal. However, if the motor has brakes, it cannot be turned manually. Check for damage. Check the overall appearance, and check for damage or scratches resulting from transportation. Check screws for looseness. Check for looseness by using a screwdriver as necessary. If any of the above items are faulty or incorrect, contact the dealer from which you pur- chased the products or your nearest local sales representative. Appearance Nameplate Type SGML - 01AF12 Rated output Series SGML: SGML Rated current Servomotor Servomotor Rated Output type Rated torque A3:0.04HP A5:0.07HP 01:0.13HP 02:0.27HP AC SERVO MOTOR 03:0.40HP 04:0.53HP SGML-02AF12 08:1.01HP Power supply Servo A:200V B:100V motor r/min 3000 S/N Encoder specifications F: 1024P/R incremental encoder YASKAWA ELECTRIC CORPORATION JAPAN Design revision order Serial number Manufacturing Shaft specifications date 2: Straight without key Series 3: Flat key seat Rated rotation 4: Straight with key SGML Servomotor speed Option Blank: Standard (W/O brake) B: With brake (90VDC) C: With brake (24VDC) 41.2 Installation Appearance Nameplate Type Servopack type SGDL - 01 A P SERVOPACK MODEL SGDL-A5AP INPUT Series 1PHASE 4. AMPS SGDL Servopack Servo- OUTPUT 0-230VMAX 200W 2.0 AMPS Rated Ouoput A3:0.04HP A5:0.07HP pack 523116-6-1 01:0.13HP 02:0.27HP YASKAWA MADE IN JAPAN 03:0.40HP 04:0.53HP 08:1.01HP Power Supply 1 Serial number Type Σ-L Series SGDL P: For position control Output power voltage Servopack Applicable power supply 1.2.2 Installing the Servomotor Servomotor SGML type can be installed either horizontally or vertically. However, if the Ser- vomotor is installed incorrectly or in an inappropriate location, the service life will be short- ened or unexpected problems will occur. To prevent this, always observe the installation instructions described below. Before installation: Anticorrosive paint is coated on the edge of the motor shaft. Clean off the anticorrosive paint thoroughly using a cloth moistened with thinner. Anticorrosive paint is coated here NOTE Avoid getting thinner on other parts of the Servomotor when cleaning the shaft. Storage: When the Servomotor is to be stored with the power cable disconnected, store it in the following temperature range: Between -20°C and 60°C 5BASIC USES OF Σ-L SERIES PRODUCTS 1.2.2 Installing the Servomotor cont. Installation sites: The Servomotor SGML type is designed for indoor use. Install Servomotor in an environment which meets the following conditions: Free from corrosive and explosive gases Well-ventilated and free from dust and moisture Ambient temperature of 0 to 40°C Relative humidity of 20% to 80% (non-condensing) Inspection and cleaning can be performed easily If the Servomotor is used in a location subject to water or oil mist, install a shield cover over the Servomotor. Alignment: Align the shaft of the Servomotor with that of the equipment to be controlled, then connect the shafts with couplings. Install the Servomotor so that alignment accuracy falls within the range shown below. Measure this distance at four different positions in the circumference. The difference between the maximum and minimum measurements must be 0.03 mm or less. (Turn together with couplings) Measure this distance at four different positions in the circumference. The difference between the maximum and minimum measurements must be 0.03 mm or less. (Turn together with couplings) NOTE If the shafts are not aligned properly, vibration will occur, resulting in damage to the bear- ings. Mechanical shock to the shaft end must be less than 98m/s² (10G) and must be applied no more than twice. Design the mechanical system so that thrust load and radial load applied to the servo- motor shaft end during operation falls within the range shown in the following table. Thrust load and radial load TERMS 2. 1. Thrust load: Shaft-end load applied parallel to the cent- erline of a shaft Motor 1. 2. Radial load: Shaft-end load applied perpendicular to Shaft end the centerline of a shaft 61.2 Installation Allowable Radial Load Allowable Thrust Motor Type Fr [N(lb)] Load Fs [N(lb)] Reference Drawing SGML-A3 68 (15) 54 (12) SGML-A5 68 (15) 54 (12) SGML-01 78 (17) 54 (12) Fr 5 SGML-02 245 (55) 74 (16) Fs 4 SGML-03 245 (55) 74 (16) SGML-04 245 (55) 74 (16) SGML-08 392 (88) 147 (33) 1 Note The radial load and thrust load values shown above are the maximum allowed values for the sum of the load generated by motor torque and the load externally applied to the shaft. 7BASIC USES OF Σ-L SERIES PRODUCTS 1.2.3 Installing the Servopack 1.2.3 Installing the Servopack Series SGDL Servopack is a book-shaped com- pact servo controller. Incorrect installation will cause problems. Always ob- serve the installation instructions described in the next page. Storage: When the Servopack is to be stored with the pow- SGDL Servopack er cable disconnected, store it in the following temperature range: Between -20°C and 85°C Installation sites: Situation Notes on Installation Design the control panel size, unit layout, and cooling When installed in a control panel method that the temperature around the periphery of the Servopack does not exceed 50°C. Suppress radiation heat from the heating unit and a When installed near a heating temperature rise caused by convection so that the unit temperature around the periphery of the Servopack does not exceed 50°C. When installed near a source of Install a vibration isolator underneath the Servopack to vibration prevent it from receiving vibration. Corrosive gases do not immediately affect the Servopack When installed in a place but will eventually cause contactor-related devices to receiving corrosive gases malfunction. Take appropriate action to prevent corrosive gases. Avoid installation in a hot and humid place or where Others excessive dust or iron powder is present in the air. Orientation: Install the Servopack perpendicular to the wall as shown in the figure. The Servopack must be orientated as shown in the figure because it is designed to be cooled by natural convection. Ventilation Firmly secure the Servopack through three mounting holes. 81.2 Installation Installation method: When installing multiple Servopacks side by side in a control panel, observe the following installation method: Fan Fan 50 mm or more 1 Fin 50 mm or more 30 mm or more 10 mm or more a) Install Servopack perpendicular to the wall that the front panel (containing connec- tors) faces outward. b) Provide sufficient space around each Servopack to allow cooling by natural convec- tion. c) When installing Servopacks side by side, provide at least 10 mm space between them and at least 50 mm space above and below them as shown in the figure above. Install cooling fans above the Servopacks to prevent the temperature around each Servo- pack from increasing excessively and also to maintain the temperature inside the control panel evenly. d) Maintain the following conditions inside the control panel: Ambient temperature for Servopack: 0 to 50°C Humidity: 90%RH or less Vibration: 0.5G (4.9 Condensation and freezing: None Ambient temperature to ensure long-term reliability: 45°C or less 9BASIC USES OF Σ-L SERIES PRODUCTS 1.2.4 Power Loss 1.2.4 Power Loss Servopack Output Current Power Loss SGDL- (Effective W Value) A Supply Voltage A3AP (30W-0.04HP) 0.42 15 200V A5AP (50W-0.07HP) 0.6 18 01AP (100W-0.13HP) 0.87 20 02AP (200W-0.27HP) 2.0 35 04AP (400W-0.53HP) 2.6 45 08AP (750W-1.01HP) 4.4 60 Supply Voltage A3BP (30W-0.04HP) 0.63 17 100V A5BP (50W-0.07HP) 0.9 20 01BP (100W-0.13HP) 2.2 30 02BP (200W-0.27HP) 2.7 47 03BP (300W-0.40HP) 3.7 70 101.3 Connection and Wiring 1.3 Connection and Wiring This section describes how to connect Σ-L Series products to peripheral devices and explains a typical example of wiring the main circuit. It also describes an example of connecting to main host controllers. 1.3.1 Connecting to Peripheral Devices 11 1 1.3.2 Main Circuit Wiring and Power ON Sequence 14 1.3.1 Connecting to Peripheral Devices 1) This section shows a standard example of connecting Series products to peripheral devices and briefly explains how to connect to each peripheral device. 2) Before wiring, turn OFF the power switch and post a notice of "No Conduction". Only a qualified electrical technician should perform the wiring. 11BASIC USES OF Σ-L SERIES PRODUCTS 2.3.1 Connecting to Peripheral Devices cont. Standard connection method for Series AC Servo Drives: Digital Allows the user to set user constants or Molded-case circuit breaker (MCCB) operation references and display operation status or alarm status. The following two types are available in addition to personal Used to protect power computers: supply line. Shuts the circuit off when overcurrent is detected. Power supply: Single-phase 200 or 100 V Mount type (JUSP-OP03A) Noise filter This type can be mounted directly on the Servopack. Used to eliminate external noise from power supply line. Types: LF-205A (for SGDL-A3AP, A5AP, 01AP, 02AP, A5BP, 01BP) LF-210 (for SGDL-04AP and 02BP) Series Servopack LF-220 (for SGDL-03BP and 08AP) Magnetic contactor Brake control Turns the servo ON or OFF. relay Use a surge suppressor for the magnetic contactor. Type: HI-15E5 (30 A) Brake power supply Used for Servomotor with brake. P 90VDC Specifications N Types: LPSE-2H01 (for 200 V input) LPDE-1H01 (for 100 V input) Connector for PG Regenerative unit This wiring is required (on Servopack side) Type: JUSP-RG08 only for a Servomotor with brake Exterior type regenerative resistor Type: JUSP-RG08C Connector kits for pulse generator (PG) and for motor are not required if the following parts are ordered: Cable with terminal connectors Cable with connector and amplifier terminal 121.3 Connection and Wiring operator Personal computer 88888 1 Exclusive-use cables between personal computer and Servopack (for NEC PC or IBM PC) are available (2m, 6.6ft.). Hand-held type Type: DE9405258 (for NEC PC, D-sub 25-pin) (JUSP-OP02A-1) DE9408564 (for NEC PC half-pitch connector, 14-pin) 1-meter(3.3ft.) cable included DE9408565 (for IBM PC, IBM compatible PC, D-sub 9-pin) Cable for PG Connector terminal block conversion unit This cable is used to connect a Servomotor CN1 connector kit (Type: JUSP-TA36P) encoder to a Servopack. (Type: DP9420007) The terminal block Cable for incremental encoder (with connector on allows connection to a host controller. both ends) CN1 9.8ft: DP9320089-1 16.4ft: DP9320089-2 32.8ft: DP9320089-3 49.2ft: DP9320089-4 65.6ft: DP9320089-5 CN1 1-meter cable with CN1 connector and one end without connector 0.5-meter(1.6ft) A cable with a single connector (without connector cable with two on Servopack side) and a cable without connectors (Type: DE9404859) CN1 connectors are also available. CN1 Connector kit for PG On Servomotor side On Servopack side CN2 This connector kit is required for cables without con- nectors. For moving parts, a cable for robot must be ordered separately. Cable for motor Connector for Connector PG (on motor for motor This is a power cable for connecting a Servomotor to a side) Servopack. For a Servomotor with brake, this cable is also used to wire the brake. Without brake (connector and amplifier terminal included) 9.8ft: DP9320081-1 16.4ft: DP9320081-2 32.8ft: DP9320081-3 49.2ft: DP9320081-4 65.6ft: DP9320081-5 With brake (connector and amplifier terminal included) 9.8ft: DP9320083-1 16.4ft: DP9320083-2 32.8ft: DP9320083-3 49.2ft: DP9320083-4 65.6ft: DP9320083-5 Series Servomotor A cable without connector and amplifier terminal is also available. Connector kit for motor Connector for motor (on motor side) This connector kit is required for cables without connector and amplifier terminal. 13BASIC USES OF Σ-L SERIES PRODUCTS 1.3.2 Main Circuit Wiring and Power ON Sequence 1.3.2 Main Circuit Wiring and Power ON Sequence 1) The following diagram shows a typical example of wiring the main circuit for Series products: Single-phase 200 to 230 VAC + 10 % 50/60 Hz For 100 V Type -15 , Single-phase 100 to 115 VAC 50/60 Hz R T SGDL- U A 1MCCB V M B W C D 1FIL PG 1MC R T 1Ry CN1 1PL 34 +12 to 24V ON ALM 1Ry 1MC 35 ALM 1D 1MC 1Ry 1SUP -SG 1MCCB: Circuit breaker 1FIL: Noise filter 1MC: Contactor 1Ry: Relay 1PL: Patrol light 1SUP: Surge suppressor 1D: Flywheel diode 2) The following table shows the name and description of each main circuit terminal: Terminal Name Description Symbol T Main circuit AC Single-phase 200 to 230 VAC + , 50/60Hz* input terminal Motor connection Connect U to the red motor , V to the white motor U V W terminal terminal, and W to the blue motor terminal Ground terminal Connect to the motor ground terminal (green) for grounding purposes. Regenerative unit connection Connect to a regenerative unit when applicable. terminal * For 100 V power supply: Single-phase 100 to 115 VAC + 50/60Hz 141.3 Connection and Wiring 3) Form a power ON sequence as follows: a) Form a power ON sequence so that the power is turned OFF when a servo alarm sig- nal is output. (See the circuit diagram shown on the previous page.) b) Hold down the power ON push-button for at least two seconds. The Servopack out- puts a servo alarm signal for approximately two seconds or less when the power is turned ON. This operation is required to initialize the Servopack. 1 Power supply max 2.0 S Servo alarm (ALM) output signal NOTE After turning the power OFF, do not touch the power terminals for 5 minutes. High voltage may remain in the Servopack. Avoid frequently turning the power ON and OFF. Since the Servopack has a capacitor in the power supply, a high charging current flows (for 0.2 second) when the power is turned ON. Therefore, frequently turning the power ON and OFF causes the main power devices (such as capacitors and fuses) to deteriorate, resulting in unexpected problems. If the Servopack is turned ON immediately after being turned OFF, a power loss alarm may arise. To prevent this, always wait for the time shown in the following table before turning the power ON again: Single-phase 200 Single-phase 100 VAC Power Holding Time VAC Servopack A3AP, A5AP A3BP 6 seconds Type 01AP, 02AP, 04AP A5BP, 01BP, 02BP 10 seconds SGDL- 08AP 03BP 15 seconds 15BASIC USES OF Σ-L SERIES PRODUCTS 1.4.1 Test Run in Two Steps 1.4 Conducting a Test Run This section describes how to conduct a full test run. The test run is divided into two steps. Complete a test run in step 1 first, then proceed to step 2. 1.4.1 Test Run in Two Steps 16 1.4.2 Step 1: Conducting a Test Run for Motor without Load 18 1.4.3 Step 2: Conducting a Test Run with the Motor Connected to the Machine 22 1.4.4 Supplementary Information on Test Run 24 1.4.5 Minimum User Constants Required and Input Signals 25 1.4.1 Test Run in Two Steps Conduct the test run when wiring is complete. Generally, conducting a test run for servo drives can be difficult. However, by following the two steps described below, the test run can be performed safely and correctly. NOTE To prevent accidents, initially conduct a test run only for a servomotor under no load (i.e., with all couplings and belts disconnected). Do not run the servomotor while it is connected to a machine. The test run is divided here into steps 1 and 2. Complete the test run in step 1 first, then proceed to step 2. The purposes of each step are described on the next page. 161.4 Conducting a Test Run Step 1: Conducting a test run for the motor without load Check that the motor is wired correctly. Conduct a test run with the motor shaft disconnected Operate the mo- from the machine. tor with a Digital Operator. Purpose: To check power supply circuit wiring To check motor wiring To check I/O signal (CN1) wiring Outline: Turn the power ON. Operate the motor with a digital op- 1 erator. Check wiring. Check I/O signals (CN1). Do not connect to a machine. Conduct a test run using I/O signals. Step 2: Conducting a test run with the motor and machine connected Adjust Servopack according to machine characteristics. Connect to the machine and conduct a test run. Purpose: To perform autotuning to adjust the mo- tor according to machine characteris- tics To match the speed and direction of SGDL rotation with the machine specifications To check the final control mode SGML Outline: Perform autotuning. Adjust user constant settings. Record user constant settings. End of test run For customers who use a servomotor with a brake, refer to Section 1.4.4 Supplementary Information on Test Run before starting a test run. The following pages describe the test run procedure in detail. 17BASIC USES OF Σ-L SERIES PRODUCTS 1.4.2 Step 1: Conducting a Test Run for Motor without Load 1.4.2 Step 1: Conducting a Test Run for Motor without Load Check that the motor is wired correctly. If the motor fails to rotate properly during a servo drive test run, the cause most frequently lies in incorrect wiring. Conduct a test run for the motor without load according to the procedure described below. For customers who use a servomotor with brake, refer to Section 1.4.4 Supplemental In- formation on Test Run before starting a test run. Operate the motor with a Digital Operator. Check wiring. Do not connect to the machine. (1) Secure the servomotor. Secure servomotor to mounting holes. Secure the servomotor to mounting holes to prevent it from moving during operation. Alter- Do not connect anything to the natively, install the servomotor on the machine motor shaft and disconnect couplings and belts. (no-load status). (2) Disconnect connector CN1, then check the motor wiring in the power supply circuit. Disconnect I/O signals (CN1) are not to be used leave connector connector CN1 disconnected. CN1 (3) Short the alarm signal circuit. Power supply Because connector CN1 is disconnected, the +12 to 24V Force this relay ON. alarm signal prevents the power supply circuit 1Ry from being turned ON. Therefore, temporarily ALM (CN1-34) short the alarm signal circuit. ALM-SG (CN1-35) Short this circuit. CN1 disconnected 181.4 Conducting a Test Run (4) Turn the power ON. Normal display Turn the Servopack power ON. If the Servo- - Pot - pack is turned ON normally, the LED on the Alternately displayed Digital Operator lights up as shown in the fig- ure. Example of alarm display RF3 Refer to Section Power is not supplied to the servomotor be- - 5.2 Troubleshoot- cause the servo is OFF. ing. If an alarm display appears on the LED as shown in the figure above, the power supply 1 circuit, motor wiring or encoder wiring is incor- rect. In this case, turn the power OFF, then cor- rect the problem. (5) Operate using the Digital Operator Operation by Digital Operator 88888 Operate the motor with the Digital Operator. Check that the motor runs normally. If an alarm occurs, the power supply Refer to 3.2.2 Operating Using the Digital Op- circuit, motor wiring, or encoder erator. wiring is incorrect. (6) Connect signal lines. After turning the power OFF, re- move the short circuit. Connect connector CN1 as follows: 1Ry ALM ALM-SG (1) Turn the power OFF. (2) Retrun the alarm signal circuit shorted in the above step (3) to its original state. Connect connector CN1. (3) Connect connector CN1. (4) Turn the power ON again. (7) Check input signals. Example of Un-05 Internal status bit display (Un-05, Un-06) Check the input signal wiring in monitor mode. For the checking method, refer to 3.1.6 Opera- tion in Monitor Mode. S-ON P-CON P-OT N-OT (CN1-14) (CN1-17) (CN1-16) (CN1-17) The memory switch can be used to eliminate the need for external short-circuits in wiring (see page 52). 19BASIC USES OF Σ-L SERIES PRODUCTS 1.4.2 Step 1: Conducting a Test Run for Motor without Load cont. Checking method Turn each connected signal line ON and OFF to check that the monitor bit display changes accordingly. Input Signal ON/OFF Monitor Bit Display High level or open OFF Extinguished 0 V level ON Lit If the signal lines below are not wired correctly, the motor fails to rotate. Always wire them correctly. (If signal lines are not to be used, short them as necessary.) P-OT CN1-16 Motor can rotate in forward direction when this input signal is at V. N-OT CN1-17 Motor can reverse when this input signal is at 0 V. S-ON CN1-14 Servo is turned ON when this input signal is at 0 V. However, leave the servo in OFF status. (8) Turn servo (motor) ON. Servopack Servomotor S-ON Turn the servo ON as follows: (CN1-14) (1) Check that no reference has been input. Turn the servo ON PULS (CN1-1) and SIGN (CN1-3) are fixed. (2) Turn the servo ON signal ON. Display when servo is turned ON Set S-ON (CN1-14) to 0 V. If normal, the motor is turned ON and the Digital Operator displays the data as shown in the figure. If an alarm dis- play appears, take appropriate action as de- scribed in Section 5.2 Troubleshooting. (9) Operate by reference input. The operating procedures are as follows: (1) Set user constant Cn-02 so that the reference pulse form matches the host con- troller output form. (See page 78 for details on how to set user constants.) Selecting reference pulse form (See page 34) Bit 3 Cn-02 Bit 4 Bit 5 201.4 Conducting a Test Run (2) Input a slow speed pulses from the host Host controller Servopack controller and execute low-speed operation Servomotor Refer- PULS (CN1-1) ence *PULS pulse (CN1-2) SIGN (3) Check the following items in monitor JUL (CN1-3) *SIGN (CN1-4) mode (see page 83): (1) Has a reference pulse been input? (2) Is the motor speed as set? 1 (3) Does the reference speed match the actual motor speed? (4) Does the motor stop when no reference is input? Un-00 Actual motor speed Un-07 Reference pulse speed display Un-08 Position error (4) To change motor speed or the direction of rotation, reset the user constants shown below. Cn-24,Cn-25 Electronic gear ratio (see page 41) Cn-02 bit 0 Reverse rotation mode (see page 30) If an alarm occurs or the motor fails to rotate during the above operation, connec- tor CN1 wiring is incorrect or the user constant settings do not match the host con- troller specifications. In this case, check the wiring and review the user constant settings, then repeat step 1. Refer to Appendix List of User Constants. This is all that is required to complete step 1 (conducting a test run for motor without load). Whenever possible, perform tuning associated with the host controller and other neces- sary adjustments in step 1 (before installing the motor on the machine). 21BASIC USES OF SERIES PRODUCTS 1.4.3 Step 2: Conducting a Test Run with the Motor Connected to the Machine 1.4.3 Step 2: Conducting a Test Run with the Motor Connected to the Machine After step 1 is complete, proceed to step 2 in which a test run is conducted with the motor connected to the machine. The purpose of step 2 is to adjust the Servopack according to the machine characteristics. Conduct a test run according to the procedure described below. Purposes: 1) Autotuning 2) Speed adjustment SGDL Servomotor Servopack Connect to the machine. NOTE Before proceeding to step 2, repeat step 1 (conducting a test run for the motor without load) until you are fully satisfied that the test has been completed successfully. Operation faults that arise after the motor is connected to the machine not only damage the machine but may also cause an accident resulting in injury or death. Therefore, all items including user constants setting and wiring should be tested as conclusively as possible before step 1 is complete. (1) Check that power is OFF. Power Servopack Turn the Servopack power OFF. supply R T Power OFF (2) Connect the servomotor to the machine. Install servomotor on machine. Refer to 1.2.2 Installing the Servomotor. Servomotor / (3) Perform autotuning. Tune the Servopack according to the mach Autotuning: characteristics. Refer to 3.2.3 Autotuning. Automatically measures machine characteristics and performs optimum tuning SGDL SGML Servopack Servomotor 221.4 Conducting a Test Run (4) Operate by reference input. Host Servopack As in step 1 (conducting a test run for motor controller without load), perform (9) Operate by refer- Servomotor ence input on page 20. Perform tuning Reference associated with the host controller. (5) Set user constants and record the settings. Set user constants as necessary. Record all Servopack 1 the user constant settings for maintenance User constants purposes. Record the settings This is all that is required to conduct the test run. Normally, the machine may cause much friction because of an insufficient running-in pe- riod. After a test run is complete, perform adequate running-in. 23BASIC USES OF SERIES PRODUCTS 1.4.4 Supplementary Information on Test Run 1.4.4 Supplementary Information on Test Run When using a servomotor with a brake, always refer to the information described below be- fore starting a test run: 1) When using a servomotor with brake The brake prevents the motor shaft from rotating due to a backdriving torque. Such a torque may be created by an external force or the force of gravity acting on the load and may result in undesired motion or the load, should motor power be lost. Servopack uses the brake interlock output (BK) signal to control holding brake operation for a servomotor with brake. Vertical axis Axis to which external force is applied Servomotor Holding brake External force Servomotor Prevents the motor from rotating due to gravity NOTE To prevent faulty operation caused by gravity (or external force), first check that the motor and holding brake operate normally with the motor disconnected from the machine. Then, con- nect the motor to the machine and conduct a test run. For wiring of a servomotor with a brake, refer to 2.4.2 Using Holding Brake. Power supply: single-phase 200 V or 100 V Brake control relay Servopack Cable for motor with brake 9.8ft DP9320083-1 16.4ft DP9320083-2 32.8ft DP9320083-3 Brake power supply 49.2ft DP9320083-4 LPSE-2H01 (200 V input) 65.6ft DP9320083-5 LPDE-1H01 (100 V input) Servomotor with brake 241.4 Conducting a Test Run 1.4.5 Minimum User Constants Required and Input Signals 1) This section describes the minimum user constants that must be set to conduct a test run. For details on how to set each user constant, refer to 3.1.5 Operation in User Constant Setting Mode. Cn-02 bits 3,4,5 Reference pulse form selection Cn-24 Electronic gear ratio (numerator) Cn-25 Electronic gear ratio (denominator) 1 2) If the specified direction of rotation differs from the actual direction of rotation, the wiring may be incorrect. In this case, recheck the wiring and correct it accordingly. Then, if the direction of rotation is to be reversed, set the following user constant: Cn-02 (bit 0) Reverse rotation mode (see page 30) After changing the Cn-02 setting, always turn the power OFF, then ON. This makes the new setting valid. 3) The following table lists the minimum input signals required to conduct a test run. For de- tails of each input signal, refer to the relevant page. Pin Signal Name Function Number Switching between motor ON and OFF status. The S-ON (servo ON) CN1-14 memory switch can be used to eliminate the need for external short-circuit wiring (see page 52). (forward P-OT rotation CN1-16 prohibited) Overtravel limit switch The memory switch can be used to eliminate the (revere need for external short-circuit wiring (see page 32). N-OT rotation CN1-17 prohibited) 25APPLICATIONS OF SERIES 2 PRODUCTS This chapter is prepared for readers who wish to learn more about the applica- tions of Σ-L series products after fully understanding Chapter 1 Basic Uses of Σ-L series Products. It explains how to set user constants for each purpose 2 and how to use each function. Read the applicable sections according to your requirements. 2.1 Setting User Constants According to Machine Characteristics 30 2.1.1 Changing the Direction of Motor Rotation 30 2.1.2 Setting the Overtravel Limit Function 31 2.2 Setting User Constants According to Host Controller 33 2.2.1 Inputting Position Reference 33 2.2.2 Using Contact I/O Signals 37 2.2.3 Using Electronic Gear 39 2.3 Setting Up the Servopack 43 2.3.1 Using Autotuning Function 43 2.3.2 Setting Servo Gain 43 2.3.3 Using the Smoothing Function 45 2.3.4 Setting the Torque Reference Filter Time Constant 46 2.4 Setting Stop Mode 47 2.4.1 Dynamic Brake 47 2.4.2 Using Holding Brake 48 2.5 Forming a Protective Sequence 51 2.5.1 Using Servo Alarm Output 51 2.5.2 Using Servo ON Input Signal 52 2.5.3 Using Positioning Complete Signal 53 2.5.4 Handling of Power Failure 54 27Chapter Table of Contents, Continued 2.6 Special Wiring 56 2.6.1 Wiring Instructions 56 2.6.2 Wiring for Noise Control 58 2.6.3 Using More Than One Servo Drive 63 2.6.4 Using Regenerative Units 64 2.6.5 Using SGDL Servopack with High Voltage Line 66 2.6.6 Connector Terminal Layouts 68 282.2Setting User Constants According to Host Controller Before Reading this Chapter 1) This chapter describes how to use each CN1 connector I/O signal for the SGDL Servo- pack and how to set the corresponding user constant. 2) For a list of I/O signals of CN1 connecor, refer to Appendix B List of I/O Signals. For terminal arrangement for I/O signals of CN1 connecor, refer to 2.6.6 Connector Ter- minal Layouts. R CN1 SGDL-01AP 200V I/O signals Host controller, external circuit 2 CN2 3) For a list of user constants, refer to Appendix C List of User Constants. 4) User constants are divided into the following two types. 1) Memory switch Set each bit to ON or OFF to select a function. Cn-01 and Cn-02 2) Constant setting Set a numerical value such as speed loop Cn-04 and later gain. SGDL Servopack User constants : 5) For details on how to set user constants, refer to 3.1.5 Operation in User Constant Setting Mode. 29APPLICATIONS OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. 2.1 Setting User Constants According to Machine Characteristics This section describes how to set user constants according to the dimensions and performance of the machine to be used. 2.1.1 Changing the Direction of Motor Rotation 30 2.1.2 Setting the Overtravel Limit Function 31 2.1.1 Changing the Direction of Motor Rotation 1) This Servopack provides a reverse rotation mode in which the direction of rotation can be reversed without altering the servomotor wiring. With the standard setting, forward rotation is defined as counterclockwise (CCW) when viewed from the drive end. 2) If reverse rotation mode is used, the direction of motor rotation can be reversed without other items being changed. The direction (+/-) of axial motion is reversed. Standard Setting Reverse Rotation Mode Forward Run Reference CCW CW Reverse Run Reference CW CCW 3) Setting Reverse Rotation Mode: Set bit 0 of memory switch Cn-02 to select reverse rotation mode. Cn-02 Bit 0 Rotation Direction Selection Factory Setting: 0 Set the direction of rotation. Setting Meaning n Forward rotation is defined as 0 counterclockwise (Standard rotation when viewed setting) from the drive end. Forward rotation is (Reverse defined as clockwise 1 rotation rotation when viewed mode) from the drive end. 302.2Setting User Constants According to Host Controller 2.1.2 Setting the Overtravel Limit Function 1) The overtravel limit function forces the moving part of the machine to stop when it ex- ceeds the movable range. Use the dynamic brake to force the motor to stop. 2) To use the overtravel limit function, connect the following input signal terminals correctly. Forward Rotation Prohibited Input P-OT CN1-16 (Forward Overtravel) Reverse Rotation Prohibited Input N-OT CN1-17 (Reverse Overtravel) Inputs terminals for overtravel limit switch. Reverse Forward 2 rotation side rotation side For linear motion, connect a limit switch to prevent Servomotor damage to the machine. Limit switch Servopack P-OT CN1-16 N-OT CN1-17 P-OT ON: CN1-16 is Forward rotation allowed. Normal operation status. at low level. OFF: CN1-16 Forward rotation prohibited (reverse rotation allowed). is at high level. N-OT ON: CN1-17 is Reverse rotation allowed. Normal operation status. at low level. OFF: CN1-17 Reverse rotation prohibited (forward rotation allowed). is at high level. 31APPLICATIONS OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. 3) Use the following user constants (memory switch) to specify whether input signals for overtravel are to be used. Cn-01 Bit 2 Use of P-OT Input Signal Factory Setting: 0 Cn-01 Bit 3 Use of N-OT Input Signal Factory Setting: 0 Specifies whether the P-OT input signal for pro- hibiting forward rotation at overtravel (CN1-16) is CN1 to be used and whether the N-OT input signal for -16 (P-OT) prohibiting reverse rotation at overtravel -17 (CN1-17) is to be used. (N-OT) The short-circuit wiring shown in the Specifies "1" when external short-circuit wiring is figure can be omitted when P-OT and to be omitted. N-OT are not used. Bit Setting Meaning Uses the P-OT input signal for prohibiting forward rotation. (Forward 0 rotation is prohibited when CN1-16 is open. Forward rotation is allowed when CN1-16 is at 0 V.) Bit 2 Does not use the P-OT input signal for prohibiting forward rotation. 1 (Forward rotation is always allowed. This has the same effect as shorting CN1-16 to 0 V.) Uses the N-OT input signal for prohibiting reverse rotation. (Reverse 0 rotation is prohibited when CN1-17 is open. Reverse rotation is allowed when CN1-17 is at 0 V.) Bit 3 Does not use the N-OT input signal for prohibiting reverse rotation. 1 (Reverse rotation is always allowed. This has the same effect as shorting CN1-17 to 0 V.) 322.2Setting User Constants According to Host Controller 2.2 Setting User Constants According to Host Controller This section describes how to connect a Σ-L series Servo to a host controller and how to set user constants. 2.2.1 Inputting Position Reference 33 2.2.2 Using Contact I/O Signals 37 2.2.3 Using Electronic Gear 39 2.2.1 Inputting Position Reference 2 1) Input a position reference by using the following input signal "reference pulse input." Since there are several specifications for input signal, select reference input for the sys- tem to be created. Inputs a move reference by pulse Servopack input. PULS CN1-1 Reference pulse *PULS P CN1-2 Position reference can correspond input SIGN CN1-3 to the following three types of out- Reference sign P input *SIGN CN1-4 put form: CLR CN1-5 Error counter clear input *CLR P CN1-6 Line driver output +12V Open collector output Represents twisted-pair cables +5V Open collector output Connection Example 1: Line Driver Output Line Driver Used: Host controller Servopack Line driver Photocoupler SN75174 manufactured by PULS CN1-1 Texas Instruments Inc., or P MC3487 or equivalent. *PULS CN1-2 SIGN CN1-3 P *SIGN CN1-4 CLR CN1-5 P *CLR CN1-6 33APPLICATIONS OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. Connection Example 2: Open Collector Output Sets the value of limiting re- Host controller Servopack sistor R1 SO that input cur- rent i falls within the following Vcc R1 i range: PULS CN1-1 Photocoupler P *PULS CN1-2 Input Current i: 7 to 15 mA Tr1 Examples: R1 SIGN CN1-3 When Vcc is 12 V, P *SIGN CN1-4 R1 = 1 R1 0 CLR CN1- When Vcc is 5 V, P *CLR CN1-6 R1 = 180 Ω 1P: Represents twisted-pair cables Note The signal logic for open collector output is as follows. When Tr1 is ON Equivalent to high level input When Tr1 is OFF Equivalent to low level input 2) Use the following memory switch to select the reference pulse form to be used: Input PULS CN1-1 Reference Pulse Input Input * PULS CN2-2 Reference Pulse Input Input SIGN CN3-3 Reference Sign Input Input * SIGN CN4-4 Reference Sign Input The motor only rotates at an angle proportional to the input pulse. Reference Pulse Form Selection Cn-02 Bit 3 Factory Setting: 0 Reference Pulse Form Selection Cn-02 Bit 4 Factory Setting: 0 Reference Pulse Form Selection Cn-02 Bit 5 Factory Setting: 0 Sets the form of a reference pulse that is external- Host controller Position Servopack ly output to the Servopack. reference pulse PULS Sets the pulse form according to the host control- (CN1-1) (CN1-3) ler specifications. SIGN 342.2Setting User Constants According to Host Controller Cn-02 Refer- Input Pulse Multi- ence Motor Forward Run Motor Reverse Run Bit Bit Bit plier Pulse Reference Reference 5 4 3 Form Sign + pulse PULS PULS 0 0 0 (CN1-1) train (CN1-1) SIGN "H" SIGN "L" (CN1-3) (CN1-3) Two- 90° phase PULS PULS 0 1 0 pulse (CN1-1) (CN1-1) train SIGN SIGN with (CN1-3) (CN1-3) 90° 0 1 1 phase 90° 2 differ- PULS PULS (CN1-1) (CN1-1) ence SIGN SIGN 1 0 0 X4 (CN1-3) (CN1-3) CW pulse + PULS PULS 0 0 1 (CN1-1) CCW (CN1-1) SIGN "L" pulse SIGN (CN1-3) (CN1-3) Input Pulse Multiply Function: 8 Number of motor move 6 When the reference form is two-phase pulse pulses 4 train with 90° phase difference, the input pulse 2 multiply function can be used. 0 Input reference pulse PULS (CN1-1) SIGN The electronic gear function can also be used (CN1-3) to convert input pulses. Example of I/O Signal Generation Timing Servo ON ON Release t1 30 ms Base block 11 t2 6 ms H (When user CN1-3 constant Cn-12 is H Sign + set to 0) L pulse train CN1-1 t3 ≥ 40 ms H L t4, t5, t6 2 ms PA PG pulse H t7 ≥ 20 L PB 15 14 16 COIN ON ON CLR Note The interval from the time the servo ON signal is turned ON until a reference pulse is input must be at least 40 ms. Otherwise, the reference pulse may not be input. The error counter clear (CLR) signal must be ON for at least 20 us. Otherwise, it be- comes invalid. 35APPLICATIONS OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. Allowable Voltage Level and Timing for Reference Pulse Input Reference Pulse Form Electrical Specifications Remarks Sign + pulse train input The signs for each (SIGN + PULS signal) reference pulse are as SIGN 17 Maximum reference follows: frequency: 225 kpps PULS High level 14 T Low level 15 16 reference reference 11, 12 â 0.1 1.1 13. 17 0.1 14. > 90° different two-phase Phase A User constant Cn-02 12 pulse train Phase B (bits 3, 4 and 5) is used (phase A + phase B) PULS to switch the input pulse SIGN multiplier mode. T T + B 11. X 100 50% CCW pulse + CW pulse Maximum reference CCW pulse T CW pulse frequency: 225 kpps PULS 12 SIGN + + reference reference 0.1 us 13 X 100 50% T 3) The following describes how to clear the error counter. Input CLR CN1-5 Error Counter Clear Input Input *CLR CN1-6 Error Counter Clear Input Setting the CLR signal to high level does the fol- lowing: Servopack CLR Sets the error counter inside the Servopack to 0. Clear Prohibits position loop control. Position loop error counter Use this signal to clear the error counter from the host controller. Bit A of memory switch Cn-02 can be set that the error counter is cleared only once when the leading edge of an input pulse rises. Cn-02 Bit A Error Counter Clear Signal Selection Factory Setting: 0 362.2Setting User Constants According to Host Controller Selects the pulse form of error counter clear signal CLR (CN1-5). Setting Meaning Clears the error counter when the CLR signal is set at high level. Error pulses CLR "H" 0 do not accumulate while the signal (CN1-5) Cleared state remains at high level. Clears the error counter only once when the rising edge of the CLR signal rises. CLR "H" 1 (CN1-5) Cleared only once at this point 2 2.2.2 Using Contact I/O Signals 1) Contact Input Signal Terminal Connections These signals are used to control SGDL Servopack operation. Connect these signal ter- minals as necessary. Servopack External power supply +12 ~ 24 V P-IN CN1-13 Host controller Photocoupler S-ON CN1-14 5 mA P-CON CN1-15 P-OT CN1-16 N-OT CN1-17 ALMRST CN1-18 Note Provide an external I/O power supply separately. There are no power terminals to which the SGDL Servopack outputs signals externally. External Power Supply: +12 to 24 VDC 30 mA or more 37OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. Yaskawa recommends that this external power supply be the same type as for the output circuit. Input P-IN CN1-13 I/O Power Supply This external power supply input terminal is com- Servopack mon to the following contact input signals: External power supply +12 to 24V P-IN CN1-13 Contact Input Signals: S-ON (CN1-14) P-CON (CN1-15) Connect an external I/O power supply. P-OT (CN1-16) N-OT (CN1-17) ALMRST (CN1-18) 2) Contact Output Signal Terminal Connections These output signals are used to indicate SGDL Servopack External Servopack operation status. power supply +12 24 V Photocoupler CN1-34 ALM MAX 50 mA Photocoupler output CN1-35 ALM-SG Per output Photocoupler CN1-7 BK Maximum operational MAX 50 mA voltage: 30 VDC Maximum output CN1-8 COIN current: 50 mA DC CN1-10 SG-COM Open collector output Per output CN1-32 PCO Maximum operational voltage: 30 VDC CN1-33 SG-AL Host controller Maximum output current: 20 mA DC Note Provide an external I/O power supply separately. There are no power terminals to which the SGDL Servopack outputs signals ex- ternally. Yaskawa recommends that this external power supply be the same type as for the input circuit. Output SG-COM CN1-10 Output Signal Ground Common This signal ground is used for the following output signals. Connect to 0 V on the external power supply. Contact Output Signals: BK (CN1-7) COIN (CN1-8) 382.2Setting User Constants According to Host Controller 2.2.3 Using Electronic Gear 1) Outline The electronic gear function enables the motor travel distance per input reference pulse to be set to any value. It allows the host controller to perform control without having to consider the machine gear ratio and the number of encoder pulses. When Electronic Gear Function When Electronic Gear Func- is Not Used tion is Used Workpiece Reference unit: 1 µm Workpiece Number of Ball screw encoder pitch: 6 mm 2 Number of Ball screw pulses: 1024 encoder pitch: 6 mm pulses: 1024 Machine conditions and reference unit To move a workpiece 10 mm, must be defined for the electronic gear function beforehand. One revolution is equivalent to 6 mm, 10 ÷ 6 = 1.6666 (revolutions) 1024 X 4 (pulses) is equivalent to one revolution, To move a workpiece 10 mm: 1.6666 X 1024 X 4 = 6827 (pulses) Reference unit is 1 A total of 6827 pulses must be input as a reference. 10 mm ÷ 1 = 10,000 pulses the host controller needs to make this calculation. 2) Setting the Electronic Gear Calculate the electronic gear ratio (B/A) according to the procedure below and set the value in Cn-24 and Cn-25. a) Check the machine specifications. Items related to electronic gear: - Gear ratio Ball screw pitch - Ball screw pitch Gear ratio - Pulley diameter 39OF Σ-L SERIES PRODUCTS 2.2.1 Inputting Position Referencecont. b) Determine the reference unit to be used. Reference unit is the minimum unit of posi- To move a table in 0.001 mm units Reference unit: 0.001 mm tion data used for moving the load. (Minimum unit of reference from host con- troller) Examples: 0.01 mm, 0.001 mm, 0.1°, 0.01 inch Determine the reference unit according to machine specifications and positioning Reference input of one pulse moves the load accuracy. by one reference unit. Example: When reference unit is 1 µm If a reference of 50000 pulses is input, the load moves 50 mm (50,000 X 1 c) Determine the load travel distance per revolution of load shaft in reference units. Load travel distance per revolution of load shaft (in reference units) Load travel distance per revolution of load shaft (in unit of distance) = Reference unit Example: When ball screw pitch is 5 mm and reference unit is 0.001 mm 5/0.001 = 5,000 (reference units) Ball Screw Disc Table Belt & Pulley Load shaft Load shaft D Load shaft P: Pitch 1 revolution D: Pulley diameter 1 revolution 360° P = Reference unit 1 revolution Reference unit πD = Reference unit d) Determine the electronic gear ratio If the load shaft makes "n" revolutions when the motor shaft makes "m" revolutions, the gear ratio of motor shaft and load shaft is n/m Electronic gear ratio = Number of encoder pulses X 4 X m/n Travel distance per revolution of load shaft (in reference units) SGME Servomotor number of encoder pulses: 1024 402.2Setting User Constants According to Host Controller NOTE Make sure that the electronic gear ratio meets the following condition: 0.01 ≤ Electronic gear ratio 100 If the electronic gear ratio is outside this range, the Servopack does not work properly. In this case, modify the load configuration or reference unit. e) Set the electronic gear ratio in the user constants below. Reduce the electronic gear ratio to their lowest terms so that both A and B are an integer smaller than 65535, then set A and B in the following user constants. 2 Cn-24 RATB Electronic gear ratio (numerator) Cn-25 RATA Electronic gear ratio (denominator) This is all that is required to set the electronic gear. RATB Unit: Setting Factory Cn-24 Electronic Gear Ratio (Numerator) None Range: 1 Setting: 4 to 65535 RATA Unit: Setting Factory Cn-25 Electronic Gear Ratio (Denominator) None Range: 1 Setting: 1 to 65535 Input Servopack reference Servomotor pulse Electro- nic gear Electronic gear ratio = Cn-25 Cn-24 A B = [(Number of encoder pulses) X 4] X [Motor shaft rotating speed] A = [Reference unit (load travel distance per revolution of load shaft)] X [Load shaft rotating speed] Note that the user constant settings must meet the following condition: 0.01 ≤ ≤ 100 41